Offline 600W Battery Charger:

PFC + LLC with HR1211

REFERENCE DESIGN

DOWNLOAD THE FULL REFERENCE DESIGN


For more information on reference designs

Contact Us

Response within 2 business days

The EVHR1211-Y-00B is an evaluation board for lithium-ion batteries, which are typically used in e-mobility and uninterruptible power supply (UPS) applications. The EVB can also be used as a general power supply unit. The device regulates the output voltage to 58.8V if there is not a battery present. This solution is based on a PFC + LLC combo controller from a single integrated circuit (the HR1211).

Instead of using costly, low-frequency filters, the EVHR1211-Y-00B offers excellent power factor levels with active power factor correction (PFC). The design shows high power density with low overall cost. In the place of diodes, synchronous rectification (SR) reduces the voltage drop, and constant current (CC) and constant voltage (CV) control ensures the battery is charged properly.

Lithium-ion batteries generally require a battery management system (BMS) to ensure that the battery operates within safe parameters. This charger can interact with a BMS through a relay signal. This helps prevent high-current spikes in the output connection, which can trigger BMS protections.

Electromagnetic compatibility (EMC) tests, harmonic emission tests, and no-load consumption tests were utilized to ensure that this solution meets industry standards.

Features

  • Wide 85V to 265V Operating Input Range
  • 14S battery configuration (3.6V)
  • High Efficiency, Up to 92%
  • Meets EuP Lot 6 and COC Version 5 Tier 2 Specifications
  • Meets Class A IEC61000-3-2 Standards
  • Meets EN55032 Class B Standards
  • High Power Factor (PF)
  • Overload Protection (Auto-Restart Mode)
  • Short-Circuit Protection (SCP) (Auto-Restart Mode)
  • Over-Voltage Protection (OVP)
  • Anti-Capacitive Mode Protection
  • Form Factor: 190 mm x 100 mm x 50 mm (3U rack STD)
600w battery charger

Applications

  • e-Bike Battery Chargers
  • Rack UPS

Block Diagram

Related Solutions

MPS Integrated Circuit Description
HR1211 High-performance digital PFC + LLC combo controller
HF500-15 Fixed-frequency flyback regulator
MP6925A Synchronous Rectifier (SR) controller
MP2009 Low Drop Out (LDO) voltage regulator

System Specifications

Parameter Specification
Input voltage range 85VAC to 265VAC
Output voltage range 35VDC to 58.8VDC (±1.5%)
Output current 10A (±1.5%)
Normal conditions Input: 230VAC, output: 50.4VDC/10A (14S Li-ion STD)
Board form factor 220mm x 100mm x 50mm
Efficiency >92%
Standby power consumption Meets EuP Lot 4 and COC Version 5 Tier 2 (<500mW at 265V) standards
Conducted emissions Meets Class B EN55032 standards
Output voltage ripple ±100mV at full load
Output current ripple ±485mA at full load

Test Overview

Efficiency vs. load

Efficiency Vs. Load

output current vs. output voltage

Output Current vs. Output Voltage

current harmonic

Current Harmonic Distribution

efficiency vs vin

Efficiency Vs. Input Voltage

power factor

Power Factor